Toothbrush

ABSTRACT

A toothbrush may comprise a handle including an internal cavity, a first opening for receiving objects in the cavity, and a second opening for a button. A neck of the toothbrush may comprise a linking portion and a head portion. The first opening and the linking portion may be sized so that the linking portion of the neck slides inside the first opening of the handle. A button element comprising a pressing portion and a sealing portion, may be formed of a flexible material and formed in the second opening of the handle to seal the second opening. An electronic module may comprise a light element that may be activated by the button. When assembled, the linking portion may be inserted in the first opening and the electronic module may be contained within the handle or within the handle and the neck.

FIELD OF THE INVENTION

The invention relates to toothbrushes, and in particular toothbrushes for children. The invention also particularly relates to a toothbrush which has a timer element. The invention also relates to a method of manufacturing the toothbrush. The toothbrush is designed to be very simple so that it is cheap and easy to manufacture in large volumes with a low rate of defects.

BACKGROUND TO THE INVENTION

Toothbrushes are everyday devices for use in cleaning teeth. Teaching children good oral hygiene is important as this can establish good habits for a lifetime. It is well known that brushing teeth adequately takes a certain amount of time and it can sometimes be difficult for children to learn how long is enough. Various toothbrushes with built in timers are known. Timers typically work for two minutes as this is the recommended cleaning time. One known method of timing is to use a flashing light. The flashing light is activated by a button on the toothbrush and a translucent or transparent part of the toothbrush is intermittently lit up whilst the child should be cleaning their teeth. This makes the toothbrush fun to use and easy for the child to learn how long is required to adequately brush their teeth.

Flashing timer toothbrushes typically are constructed with a handle having a cavity containing an electronic module with an LED, and a button on the handle for operating the electronic module. Typically, the handle is made of several parts which are injection moulded and welded together or held together with a snap fit or pin. Such toothbrushes suffer from several problems. In particular, joints may allow ingress of water into the cavity. This is both unhygienic and may affect the electronic module. Furthermore, the water may subsequently leak out of the handle and be unpleasant to the user. Another problem is that joints are typically welded using ultrasonic welding. Ultrasonic welding requires machinery that must be “tuned” to provide a good joint. These machines may go out of “tune” and therefore require regular maintenance. When the machinery is not well-turned a certain number of toothbrushes will be produced which are not up to the required standard. Furthermore, the vibration caused during ultrasonic welding may damage the electronic components of the toothbrush within the cavity.

One aim of the invention is to provide a toothbrush that is very simple to make, so that it is cheap and easy to produce in large volumes. Another aim is to provide a toothbrush that is safe for children and is easy to use. Other aims of the invention will become apparent from the following description and claims.

SUMMARY OF THE INVENTION

Aspects of the invention are set out in the accompanying claims.

One aspect of the invention relates to a toothbrush, comprising: a handle formed of a first material, comprising: an internal cavity, a first opening for receiving objects in the cavity, and a second opening for a button; a neck comprising a linking portion, a collar, a neck portion and a head portion, wherein the opening in the handle and the linking portion of the neck are suitably sized so that the linking portion of the neck slides inside the first opening of the handle and has a tight fit, and the collar limits the distance that the neck may slide into the handle; a button element comprising a pressing portion and a sealing portion, wherein the button element is formed of a second material different to the first material, the second material is more flexible than the first material, and the button element is formed in the second opening of the handle to seal the second opening; and an electronic module comprising a light element that may be activated by the button; wherein, when assembled, the linking portion of the neck is inserted in the first opening of the handle and the electronic module is contained within the handle, or the electronic module is contained within the handle and the neck.

The handle, neck and electronic module are separate components. The toothbrushes are of simple construction, having only three main parts, with the electronic module inserted in the handle and an end of the neck also being inserted in the handle. The electronic module is completely contained within the handle or the handle and the neck. This makes the toothbrush very simple and easy to construct, thus, making it cheap and easy to produce in large volumes. A button is formed in the handle from a second material that is more flexible than the material of the handle. Therefore, the button is elastic and easy for a child to activate. The button may also have high tensile strength so that it does not tear easily. As the handle is made from a single shot injection mould process, there is no need for welds between the parts of the handle. Therefore, the chamber for holding the electronic module is completely watertight.

The internal cavity may be completely sealed and waterproof. Furthermore, when assembled, a sealing member may be located between the neck and the handle. The button is moulded to the handle in such a way that the join is waterproof and difficult to remove. As the button seals the second opening in the handle and the connection between the neck and the handle are sealed, all of the openings to the toothbrush are sealed. There is no possibility that water may ingress into the internal cavity.

A pin may be inserted through the handle and neck with an interference fit. This secures the neck to the handle. Furthermore, the design preferably does not allow access to the internal parts once the toothbrush is assembled. For example, the batteries cannot be accessed which improves child safety.

The sealing member may be a silicone ring and the distance between the hole for receiving the interference pin on the collar, on the linking portion of the neck and the back of the handle is such that when assembled the sealing member is compressed, thus ensuring that it forms a watertight seal between the handle and neck.

Also, the design is simplified by the construction and assembly of the electronic module. The electronic module is a complete and discrete part which may be inserted in the handle or the neck and the handle. The electronic module does not need to be secured to the handle, thus it is “floating” within the handle. If the electronic module is too small so that it does not fill the internal cavity, it may include additional tabs along its sides and/or length so that it sits securely in the handle. This also enables flexibility to the design to allow for adjustment of the exact position of the module when it is in the cavity so that the button of the handle is located next to the switch of the electronic component. Thus, when the button is pushed the light element or LED may be activated by the switch. The integrated circuit controls the LED. For example, the LED may flash for a time period of two minutes when the switch is activated.

The neck may be made of transparent or translucent material and have a cavity for receiving the LED of the electronic component. This enables the LED to be seen when inside the toothbrush.

The head portion of the neck is arranged to receive sets of bristles to form the brush.

The handle may further comprise an external cavity into which a suction cup may be inserted. The suction cup may be made from a flexible material, such as the same material as the button and formed using a second shot process. The suction cup may be used to stand the toothbrush upright when it is not in use.

Another aspect of the invention relates to a process for manufacturing a toothbrush. The process comprises the steps of moulding a handle from a first material, using a single shot injection moulding process moulding a neck using a single shot injection moulding process; forming a button from a second material, more flexible than the first material, in the handle using a second shot injection moulding process inserting an electronic module in the handle inserting a linking portion of the neck in the handle wherein the electronic module is completely contained within the handle, or the handle and neck and the internal cavity is sealed at the first and second openings of the handle.

The process is relatively simple. This makes the toothbrush easy to construct and cheap to manufacture. The process does not include ultrasonic welding and therefore does not have the disadvantages associated with this, avoiding poor results as a result of a badly tuned machine and vibration causing damage to the electronic module. Also, there are few manual processes for assembling the toothbrush, therefore keeping labour costs to a minimum.

Other aspects of the invention and their advantages will become apparent from the following description.

BRIEF DESCRIPTION OF THE DRAWINGS

The following detailed description of the preferred embodiments makes reference to the accompanying drawings in which:

FIG. 1 illustrates a front view of a known flashing toothbrush;

FIG. 2 illustrates a back view of a known flashing toothbrush;

FIG. 3 illustrates the parts of a flashing toothbrush;

FIG. 4 illustrates a handle and electronic module of a flashing toothbrush;

FIG. 5 illustrates a flashing toothbrush, back view;

FIG. 6 illustrates a flashing toothbrush, front view;

FIG. 7 illustrates a flashing toothbrush, back view;

FIG. 8 illustrates a back view of a toothbrush and a suction cup; and

FIG. 9 illustrates a flow chart diagram of the manufacturing process.

DETAILED DESCRIPTION

Referring to the drawings, like reference numerals designate identical or corresponding features throughout the views.

A typical flashing toothbrush comprises a handle and a neck. The neck is translucent or transparent. A part of the neck is inserted into the handle. An electronic module is provided within the handle. The exterior of the handle has a button element that is in communication with an electronic module. The electronic module extends into the neck of the brush. When the button is pressed, a timer is started and an LED flashes until the timer expires. The LED is visible through the neck portion.

Front and back views of a typical flashing toothbrush 200 are shown in FIGS. 1 and 2. In FIG. 2 the parts are separated. The toothbrush comprises a handle 210 and a neck 220. The handle 210 is constructed of three parts. Front and back main body parts 211 are assembled with ultrasonic welding and an access panel 213 is held to the back of the main body 211 by an interference fit. A button element 230 is formed of another material and is inserted in an opening in the handle 210. Another opening in the handle receives the electronic module 240 which is integrated with the neck 220. Thus, the handle 210 is assembled with multiple parts and has multiple openings.

When assembled a switch for controlling the electronic module is located behind the button element. When activated by the switch, an LED, visible through the neck, flashes for approximately two minutes.

In an embodiment of the invention, the handle, electronic module and neck comprise separate parts.

The handle is formed of a first material and has an internal cavity. A first opening is for receiving objects in the cavity, for example, the electronic module and a portion of the neck. The handle further comprises a second opening for a button, located on the front of the handle near to the first opening. Surrounding the second opening is a portion for receiving a button element. The button element (described in more detail below) is bonded to the handle on the exterior around the second opening so that it is sealed. In addition, a small hole is provided on the back of the handle, substantially opposite the button for receiving a pin. Moulded into the back of the handle are curved ridges which assist with gripping the handle.

The handle may optionally include an external cavity, located at or near the end opposite to the first opening, on the back of the handle. There is no communication between the external cavity and the main internal cavity of the handle. The external cavity may receive a suction cup to provide means for standing the toothbrush upright when it is not in use. In the present embodiment the external cavity is shaped with a narrow opening at the bottom of the handle that widens towards the centre of the body of the handle. This helps to ensure that the suction cup is not pulled out of the cavity when the toothbrush is picked up from a surface, when the suction cup is attached to the surface. The cavity is completely open on the back of the handle, when the suction cup is removable. This helps to ensure that the suction cup is easy to insert and/or remove from the handle. The suction cup is made from a flexible material. The suction cup is shaped with a portion to insert in the external cavity of the handle and a cup portion. The portion that is shaped to insert in the handle has a complimentary size and shape so that it may be pushed into the cavity with a snug fit. In an alternative arrangement the suction cup is formed directly in the external cavity during production of the toothbrush and is bonded to the handle. In this case the suction cup is not removable. The cup portion has a hemi-spherical shape with a relatively thin wall. The cup portion extends away from the handle so that it protrudes from the handle to make a stand. As the cup is made from a flexible material, a user may push down on the toothbrush to make a temporary seal between the cup and a surface and thereby provide a stand for the toothbrush.

The neck comprises a linking portion, a collar, a neck portion and a head portion. The linking portion of the neck is suitably sized to the slide inside the first opening of the handle. The end of the linking portion is shaped so that it surrounds and encloses the electronic module. The electronic module may therefore be held by the linking portion and carried into the internal cavity of the handle as the linking portion is inserted into the first opening of the handle. The linking portion has a cavity into which an LED may be received. The collar portion is wider than the first opening and therefore limits how far the neck may be pushed into the handle. On the linking portion of the neck, corresponding to the back of the handle, there is a small hole for receiving a pin. The head portion of the neck comprises a series of indentations or bores which are suitable for receiving sets of bristles to form a brush.

The distance between the hole in the linking portion of the neck and the collar parties and the distance between the hole in the back of the handle and the first opening of the handle are approximately the same.

A button element is located around and in the second opening of the handle, on the front of the handle. The button element is bonded to the handle and has a pressing portion and a sealing portion. The sealing portion surrounds the pressing portion, and is bonded to the handle. The button element fills the second opening of the handle. The button element is formed of a flexible material.

An electronic module, when the toothbrush is assembled, is located in the internal cavity of the handle. The electronic module comprises a light element or LED, a switch, an integrated circuit and a battery cell. The electronic module may further comprise tabs or flanges so that it is sized to snugly and securely fit within the cavity in the handle. Further, the tabs or flanges may be used to ensure that the switch of the electronic module is located directly behind the button of the handle, when assembled. For example, where the electronic module is smaller than the internal cavity, the tabs extend outwardly therefrom and are sized to contact the interior of the cavity, when inserted, so that the electronic module sits securely within the handle.

FIG. 3 shows an embodiment of the invention, in parts before they are assembled, to form a toothbrush 100. As described above, the handle 10 has a first opening and a second opening. The button element 30 is located in the second opening of the handle 10 and has a pressing portion 31 and a sealing portion 32. The neck 20 has a linking portion 11, a small hole 12 for receiving a pin, a collar 13, a neck portion 14 and head 17. The electronic module 40 has a LED 41, a switch 42, an integrated circuit and battery cell 43 and tabs 44. A suction cup 50 is shown also.

The toothbrush may further comprise a silicone ring to form a seal where the collar portion of the neck meets the first opening of the handle.

To assemble the toothbrush, the electronic module is inserted through the first opening of the handle and located within the cavity. The tabs ensure that the electronic module is secure and that the switch is positioned behind the button element. However, the electronic module is not secured to the handle and is effectively floating inside the cavity. The LED extends out of the opening, as shown in FIG. 4. Then the silicone ring is positioned over the linking portion of the neck. The neck is positioned in the first opening of the handle. The silicone ring is compressed to provide a seal between the neck and the handle. The neck is secured in position by inserting a pin that extends through the hole in the handle and the hole in the neck linking portion. The pin has a fluid tight interference fit. Thus, the pin cannot be removed and the neck is secured to the handle.

FIG. 5 shows the back of an assembled toothbrush 100. The neck 20 is secured to the handle 10 in position by the pin 60. A silicone ring 70 seals the joint between the neck 20 and the handle 10. As the other parts of the toothbrush 100 are within the handle 10 and the neck 20, the toothbrush 100 is completely sealed and may not be taken apart.

FIGS. 6 and 7 show the front and back of an assembled toothbrush 100. In these views, the toothbrush 100 is complete with bristles 18 in the head 17 of the neck 20 and a suction cup 50 located in an external cavity 14 of the handle 10. FIG. 8 shows a detail of the base of a handle 10 with the suction cup 50 removed.

Thus, the toothbrush does not comprise any welded joints and only has sealed openings. No other openings are present, and therefore the toothbrush is completely waterproof. No fluids may ingress into the cavity of the handle. Also, as it cannot (without damaging the components) be taken apart once assembled, there is no possibility of a child gaining access to the internal small parts such as the batteries of the electronic module.

The handle and neck are typically made from ABS. The neck is made from a transparent or translucent material. The button and or suction cup are made from a highly flexible material such as TPR. TPR and ABS are chosen as they bond to form a strong seal. TPR has high flexibility and tensile strength. The button is therefore very elastic and easy to activate by a child. Also, it is difficult to tear the button material away from the handle. Other suitable materials may be used.

Another embodiment provides a method of cheaply manufacturing a toothbrush. The method comprises the steps of: (a) moulding the handle from a first material using a single shot injection mould and process; (b) moulding the neck using a single shot injection moulding process; (c) forming a button from a second material, in the handle, using a second shot injection moulding process; (d) inserting the electronic module in the handle; and (e) inserting a linking portion of the neck in the handle.

The skilled person will be familiar with each of these processes. The handle is made by a single shot injection moulding process and is in one piece, therefore it does not require any ultrasonic welding. The handle is completed by forming the button and optionally the suction cup. The button is made by a second shot injection moulding process and directly formed in the second opening of the handle. The suction cup may be formed directly in the external cavity, using a similar process to the one used to form the button.

The process may further comprise the steps of: (f) securing the neck to the handle using an interference pin; and finally (g) securing bristles in the head portion of the neck.

In use, the switch may be activated by pressing the button. The electronic module starts a timer and also starts the LED flashing. When the timer expires, the LED stops flashing. Typically, the timer lasts for approximately two minutes during which time the child may clean his/her teeth.

While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate all possible forms of the invention. It is understood that various changes may be made without departing from the scope of the invention. Those of ordinary skill in the art will appreciate that any arrangement, which is calculated to achieve the same purpose, may be substituted for the specific embodiments shown and that the invention has other applications in other environments. This application is intended to cover any adaptations or variations of the present invention. The following claims are in no way intended to limit the scope of the invention to the specific embodiments described herein.

When used in this specification and claims, the terms “comprises” and “comprising” and variations thereof mean that the specified features, steps or integers are included. The terms are not to be interpreted to exclude the presence of other features, steps or components.

The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof. 

1. A toothbrush, comprising: a handle formed of a first material, comprising: an internal cavity, a first opening for receiving objects in the internal cavity, and a second opening for a button; a neck comprising a linking portion, a collar, a neck portion and a head portion, wherein the first opening in the handle and the linking portion of the neck are sized so that the linking portion of the neck slides inside the first opening of the handle and has a tight fit, and the collar limits the distance that the neck slides into the handle; a button element comprising a pressing portion and a sealing portion, wherein the button element is formed of a second material different to the first material, the second material is more flexible than the first material, and the button element is formed in the second opening of the handle to seal the second opening; and an electronic module comprising a light element, the light element configured to be activated by the button; wherein, when assembled, the linking portion of the neck is inserted in the first opening of the handle and the electronic module is contained within the handle, or the electronic module is contained within the handle and the neck.
 2. A toothbrush according to claim 1, wherein, when assembled, the internal cavity is completely sealed and waterproof.
 3. A toothbrush according to claim 1, wherein the neck is secured in position in the handle by an interference fit pin that extends through both a hole in the handle and a hole in the linking portion of the neck.
 4. A toothbrush according to claim 1, further comprising a sealing member located between the neck and the handle when assembled.
 5. A toothbrush according to claim 4, wherein a first distance between the collar and the hole in the linking portion of the neck, and a second distance between the first opening and hole of the handle are both sized to compress the sealing member when assembled.
 6. A toothbrush according to claim 4, wherein the sealing member is a silicone ring.
 7. A toothbrush according to claim 1, wherein the electronic module is floating within the handle or the handle and the neck, or the electronic module is not secured to the handle or the neck, or the electronic module is sized so that it sits securely within the handle and substantially extends the length of the handle. 8-9. (canceled)
 10. A toothbrush according to claim 1, wherein the electronic module is smaller than the internal cavity, and has one or more tabs extending outwardly therefrom, the one or more tabs sized to contact the interior of the internal cavity, so that the electronic module sits securely within the handle.
 11. A toothbrush according to claim 1, wherein the electronic module comprises a light element, a switch, and a timer, wherein, when the toothbrush is assembled, the switch is located behind the button.
 12. A toothbrush according to claim 11, wherein the light element flashes for a defined period when activated by the switch, and the neck has a neck cavity for receiving the light element.
 13. (canceled)
 14. A toothbrush according to claim 1, wherein at least a part of the neck is made from a translucent or transparent material.
 15. A toothbrush according to claim 1, wherein the head portion of the neck has at least one recess or bore for receiving at least one set of bristles.
 16. A toothbrush according to claim 1, wherein the handle further comprises an external cavity carrying a suction cup, wherein the suction cup is made from a flexible material or made from the second material. 17-19. (canceled)
 20. A toothbrush according to claim 1, wherein the handle does not comprise any welds.
 21. A toothbrush according to claim 1, wherein the first opening and the second opening are the only openings of the handle.
 22. A toothbrush according to claim 1, wherein the neck does not have any external openings which communicate with the internal cavity.
 23. A process for manufacturing a toothbrush comprising the steps of: molding a handle from a first material, using a single shot injection molding process; molding a neck using the single shot injection molding process; forming a button from a second material, more flexible than the first material, in the handle using a second shot injection molding process; inserting an electronic module in the handle; and inserting a linking portion of the neck in the handle; wherein an electronic module is completely contained within the handle, or the handle and neck, and an internal cavity of the handle is sealed at the first and second openings of the handle.
 24. A process for manufacturing a toothbrush according to claim 23, further comprising the steps of: securing the neck to the handle using an interference fit pin, and forming a suction cup using a second shot injection molding process.
 25. (canceled)
 26. A process for manufacturing a toothbrush according to claim 17, further comprising the step of securing at least one set of bristles in a head portion of the neck.
 27. A process for manufacturing a toothbrush according to claim 23, wherein the process does not include ultrasonic welding.
 28. (canceled) 